EC POWER XRGI 15 Bedienungsanleitung

INSTALLATION GUIDE

01DOC1043 VERSION 1.0 2018

FOR PROFESSIONALS

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

1. DOCUMENTATION INFORMATION 4

1.1 ORIGINAL OPERATING INSTRUCTION 4

1.2 APPLICABLE DOCUMENTS 4

1.3 KEEP THE DOCUMENTS 4

1.4 SYMBOLS USED 4

1.5 RATING PLATE 4

1.6 VALIDITY OF THE GUIDE 5

1.7 CE MARKING 5

2. SYSTEM COMPONENTS 6

2.1 MAIN XRGI® SYSTEM COMPONENTS 6

2.1.1 POWER UNIT 7

2.1.2 iQ-CONTROL PANEL 9

2.1.3 Q-HEAT DISTRIBUTOR 10

2.2 XRGI® SYSTEM ACCESSORIES 11

2.2.1 Q-NETWORK 11

2.2.1.1 STORAGE CONTROL 12

2.2.1.2 FLOW MASTER CONTROL 13

2.2.1.3 FLOW MASTER 14

2.2.1.4 BOILER CONTROL 15

2.2.1.5 VPP GATEWAY 16

2.2.1.6 ELECTRIC HEATER CONTROL 17

2.2.1.7 MODBUS GATEWAY 18

2.2.1.8 STORAGE TANK 19

2.2.1.9 LOAD SHARER S 21

3. SAFETY INSTRUCTION 22

3.1 SAFETY AND WARNING INSTRUCTIONS 22

3.1.1 SAFETY AND WARNING SYMBOLS USED 22

3.2 INTENDED USE 22

3.3 GENERAL SAFETY INSTRUCTIONS 24

3.3.1 HANDLING ENGINE OIL 24

3.3.2 ACTIONS WITH SMELL OF GAS IN BUILDINGS 25

3.3.3 ACTIONS WITH FIRE OR IGRESS OF WATER 25

3.3.4 ACTIONS WITH SMELL OF EXHAUST GAS IN BUILDINGS 25

3.3.5 FROST PROTECTION 26

3.3.6 CONTACT HAZARD 26

3.3.7 EXPLOSIVE AND EASILY FLAMMABLE MATERIALS 26

3.3.8 COMBUSTION AIR SUPPLY 26

3.3.9 MODIFICATIONS TO THE XRGI® SYSTEM COMPOUNDS 27

3.3.10 FILLING AND TOP-UP LIQUID 27

3.3.11 PROPERTY DAMAGE CAUSED BY IMPROPER USE OF AND/OR UNSUITABLE TOOLS 27

3.3.12 MODIFICATIONS IN THE VICINITY OF THE XRGI® SYSTEM 28

3.3.13 OPERATION WITH LIQUID GAS 28

3.3.14 WORKING ON THE ELECTRICAL SYSTEM 28

3.3.15 SAFETY EQUIPMENT ON THE XRGI® SYSTEM 29

3.3.16 SAFETY AND WARNING LABELS ON THE XRGI® SYSTEM 29

3.4 REGULATIONS, STANDARDS AND LAWS 30

3.5 WARRANTY INFORMATION 30

3.5.1 RETURN OBLIGATIONS 30

TABLE OF CONTENTS

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

4. ASSEMBLY 32

4.1 SCOPE OF DELIVERY CHECK – XRGI® SYSTEM 32

4.1.1 XRGI® ORIGINAL ACCESSORIES 32

4.2 TRANSPORT AND HANDLING 32

4.3 INSTALLATION ROOM 33

4.3.1 FOUNDATION 33

4.3.2 ROOM TEMPERATURE/DUST 33

4.3.3 NOISE AND VIBRATION 33

4.3.4 CORROSIVE AMBIENT CONDITIONS 34

4.3.5 REQUIRED AIR INLETS 34

4.3.6 REMOTE DATA MONITORING 34

4.4 DIMENSIONS AND CONNECTIONS 35

4.4.1 XRGI® 6/9-SYSTEM 35

4.4.2 XRGI® 15/20-SYSTEM 38

4.5 REQUIRED MINIMUM CLEARANCES – ASSEMBLY & MAINTENANCE CLEARANCES 41

4.5.1 XRGI® 6/9-SYSTEM 41

4.5.2 XRGI® 15/20-SYSTEM 42

4.6 INSTALLATION OF THE XRGI® SYSTEM 44

4.6.1 SOUND INSULATION 44

5. INSTALLATION 45

5.1 HYDRAULIC INSTALLATION 45

5.1.1 EC POWER STANDARD HYDRAULIC SYSTEM 45

5.1.2 INSTALLATION Q-HEAT DISTRIBUTOR – POWER UNIT 49

5.1.2.1 PRIMARY CIRCUIT – FLOW AND RETURN CONNECTION 49

5.1.3 INSTALLATION Q-HEAT DISTRIBUTOR – STORAGE TANK/CONSUMER NETWORK 50

5.1.3.1 SECONDARY CIRCUIT – FLOW AND RETURN CONNECTION 50

5.1.3.2 EC POWER STORAGE TANK 51

5.2 EXHAUST GAS SIDE INSTALLATION 52

5.2.1 EXTERNAL EXHAUST HEAT EXCHANGER 52

5.3 GAS SIDE INSTALLATION 53

5.3.1 GAS HOSE CONNECTION 53

5.4 ELECTRICAL INSTALLATION 54

5.4.1 POWER UNIT 54

5.4.2 Q-HEAT DISTRIBUTOR 54

5.4.3 iQ-CONTROL PANEL 54

5.4.4 POWER FACTOR CORRECTION 56

5.5 NETWORK INSTALLATION 56

5.5.1 STORAGE CONTROL 56

5.5.2 FLOW MASTER CONTROL 57

5.5.3 FLOW MASTER 57

5.5.4 BOILER CONTROL 58

5.5.5 VPP GATEWAY / ELECTRIC HEATER CONTROL 59

5.5.6 MODBUS GATEWAY 59

5.5.7 LOAD SHARER S 60

TABLE OF CONTENTS

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

1. DOCUMENTATION INFORMATION

This XRGI® installation guide provides detailed information about the individual XRGI® system components, their functions, assembling

and installation.

It provides important safety instructions that must be complied with when operating the XRGI® system and describes the interplay of

the Power Unit, the Q-Heat Distributor and the iQ-Control Panel as included in the standard scope of delivery. It also describes certain

accessories, the Q-Network modules and the storage tank, which may be required depending in the individual installation.

Please read this XRGI® installation guide carefully before installation and commission.

Only a correct assembling, installation and operation of the XRGI® system according to the speciﬁcations from EC POWER ensures proper

functioning and a valid warranty. Please keep this XRGI® installation guide for later reference. EC POWER continuously improves its pro-

ducts and reserves the right to make technical changes and to implement these changes if considered necessary. This means that the

company is not bound to make retrospective changes to already delivered XRGI® systems.

The following information’s are a guide through the entire documentation. In connection with this XRGI® installation guide. In connec-

tion with this XRGI® installation guide, other accompanying documents must be followed. EC POWER cannot take responsibility for any

damages caused by non-compliance with the instructions for the XRGI® system.

1.1 ORIGINAL OPERATING INSTRUCTION

1.2 APPLICABLE DOCUMENTS

1.3 KEEP THE DOCUMENTS

1.4 SYMBOLS USED

1.5 RATING PLATE

This XRGI® installation guide contains original operating instructions in accordance with the Machinery Directive.

When installing the XRGI® system, all installation instructions for additional components and components of the XRGI® system must

be complied with. These installation instructions are attached to the respective components of the XRGI® system and additional

components.

Please note all operating instructions that come with the components of the XRGI® system.

These documents are subject to technical modiﬁcations!

Due to the continuous development of the XRGI® systems, illustrations, functional steps and technical data may diﬀer slightly.

Pass on this XRGI® installation guide and all applicable documents to the system operator.

The system operator keeps the XRGI® installation guide and other instructions for future reference so that they are available when

needed.

The following explains the symbols used in the text.

INFO!

Symbol for important and useful information about the issue.

POWER UNIT

The rating plate is located on the back of the Power Unit.

Legend

1Power Unit serial no.

2Type description of the XRGI® system

3Description of the type approval

4Technical data of the Power Unit

5CE marking

2 5

Fig. 1.01 – Power Unit rating plate

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

2 4

With the CE marking, products comply with the essential requirements of the relevant directives in accordance with the rating plate.

Q-HEAT DISTRIBUTOR

The rating plate is located on the inside of the Q-Heat Distributor

below the electronics box.

Legend

1Q-Heat Distributor serial no.

2Type description of the Q-Heat Distributor

3Technical data of the Q-Heat Distributor

4 CE marking

iQ-CONTROL PANEL

The iQ-Control Panel has two rating plates. These are located on the inside

of the iQ-Control Panel door and on the left side of the iQ-Control Panel,

below the main switch disconnector.

Legend

1iQ-Control Panel serial no.

2 Technical data of the iQ-Control Panel

3Type description of the iQ-Control Panel

4XRGI®-ID of the XRGI® system

1.7 CE MARKING

1.6 VALIDITY OF THE GUIDE

This XRGI® installation guide only applies to XRGI® systems with the following article numbers:

■Without additional accessories

■With additional storage tank

Type Article number

XRGI® 6 X060001 / X060002

XRGI® 9 X090001 / X090002

XRGI® 15 X150001 / X150002

XRGI® 20 X200001 / X200002

Fig. 1.02 – Q--Heat Distributor rating plate

Fig. 1.04 – Rating plate iQ-Control Panel

Fig. 1.03 – iQ-Control Panel rating plate

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

An XRGI® system consists of the following three main components:

POWER UNIT

■Heat production

■Power production

■Safety functions

■Power control

IQCONTROL PANEL

■Connection to the grid

■Electrical safety features

■Control of the XRGI® system

■Status and production display

■Remote data transmission

QHEAT DISTRIBUTOR

■Regulation of the temperature of the engine water

■Connection of the XRGI® system to the storage tank and the central

heating system

■Output of high-eﬃciency pumps regulated according to current demand

■Creation of storage strategies according to current demand

■Service and error messages in the heating system

2. SYSTEM COMPONENTS

2.1 MAIN XRGI® SYSTEM COMPONENTS

An XRGI® system consists of three main components: the Power Unit, the Q-Heat Distributor and the iQ-Control Panel.

The XRGI® system can be expanded with additional XRGI® accessories: Storage Control, Boiler Control, Flow Master Control, Flow

Master, Electric Heater Control, VPP Gateway, Modbus Gateway, storage tank and Load Sharer S.

Construction of the standard XRGI® systems:

XRGI®6 Power Unit XRGI® 6 – Q20-Heat Distributor – iQ10-Control Panel

XRGI®9 Power Unit XRGI® 9 – Q20-Heat Distributor – iQ10-Control Panel

XRGI®15 Power Unit XRGI® 15 – Q80-Heat Distributor – iQ15-Control Panel

XRGI®20 Power Unit XRGI® 20 – Q80-Heat Distributor – iQ20-Control Panel

Fig. 2.01

Fig. 2.02

Fig. 2.03

Fig. 2.04

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

A B

1 4 52 6

3 7

8/9

Fig. 2.05 - XRGI® 6/9

Fig. 2.06 - XRGI® 6/9

Fig. 2.07 - XRGI® 6/9

2.1.1 POWER UNIT

CONSTRUCTION

Legend:

A Electrical components and safety circuit

B Air ﬁlter and mixture control

C Sound- and heat-insulated engine compartment

1 Silencer (integrated)

2 Water-cooled generator

3 Exhaust gas cooler (not visible)

4 Oil sump

5 EC POWER gas engine

6 Oil separator

7 Catalyst (not visible (patented))

8 Primary circuit ﬂow (1“ G)

9 Primary circuit return (1“ G)

10 Electrical connection

11 Exhaust gas connection (twin tube, di = 60 mm, da = 100 mm)

12 Gas connection (½“ G)

13 Air ﬁlter

14 Gas safety circuit

15 Cover with gas pressure springs

16 Spark plugs

17 Upright pipe for oil change

18 Oil ﬁlter (upright, water-cooled)

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

A B

1 2 5 4

3 7

61 2 5 4

3 7

CONSTRUCTION

Legend:

A Electrical components and safety circuit

B Air ﬁlter and mixture control

C Sound- and heat-insulated engine compartment

1 Silencer (integrated)

2 Water-cooled generator

3 Exhaust gas cooler (not visible)

4 Oil sump

5 EC POWER gas engine

6 Oil separator

7 Catalyst (not visible (patented))

8 Primary circuit ﬂow (1¼“ G)

9 Primary circuit return (1¼“ G)

10 Electrical connection

11 Exhaust gas connection (twin tube, di = 60 mm, da = 100 mm)

12 Gas connection: XRGI® 15: ¾“ G – XRGI® 20: ¾“ G

13 Air ﬁlter

14 Gas safety circuit

15 Cover with gas pressure springs

16 Spark plugs

17 Upright pipe for oil change

18 Oil ﬁlter (upright, water-cooled)

FUNCTION

CONFIGURATION

The Power Unit contains the following main components:

■Engine control

■Cooling circuit

■Mixture control

■Engine electronics

■Gas safety circuit

■Temperature monitoring relay

Here, gas converts into electricity and heat.

The gas setting must only be carried out by authorised persons. This is described in the commissioning instruction. No further adjust-

ments are needed on the engine.

Fig. 2.08 - XRGI®15

Fig. 2.09 - XRGI®15

Fig. 2.10 - XRGI®15

Fig. 2.12 - XRGI®20

Fig. 2.13 - XRGI®20

Fig. 2.11 - XRGI® 20

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

1 9 3 102

11 13

1 2 3 4

Legend:

1 Contactor

2 Residual current breaker (4P 40A 30mA)

3 Miniature circuit breaker

4 Fan

5 Central Control PCB with integrated modem (not visible)

6 Residual current breaker (1P+N 1A C)

7 Motherboard (not visible)

8 RJ45 connector

9 Transient protection

10 Direct power meter

11 Soft starter

12 Main switch disconnector

13 Network monitoring relay

14 Antenna

2.1.2 IQCONTROL PANEL

CONSTRUCTION

CONFIGURATION

FUNCTION

The iQ-Control Panel is used to operate the XRGI® system.

■Main switch disconnector: Main switch connector masters

on/oﬀ switch for the iQ-Control Panel and the Power Unit

INFO: The Q-Heat Distributor is powered separately!

■Soft starter: Starts the generator as an engine

■Auxiliary relay: Extra relay for the soft starter

■RCD type A: Fault protection

■Fuses: Overvoltage protection

■Output meter. measures the electricity produced by the

generator

■ENS relay: N/A protection device

■Motherboard power supply: Supplies 12V to the mainboard

■Motherboard: Communication interface with the Power

Unit and the Q-Heat Distributor

■Central Control PCB with integrated modem system

processor: Sends data to the EC POWER service database

via mobile network

The iQ-Control Panel is mainly responsible for the following:

■System control

■Power regulation

■Power meter (production)

■Hardware and software for the operating strategy

■Data collection and analysis

■Communication with the service database

■Interfaces for external connections

The iQ-Control Panel is operated using its front panel and turned on and oﬀ using the main switch disconnector on the left side.

Fig. 2.14 - iQ 10

Fig. 2.15 - iQ 15/20

XRGI®

- INSTALLATION GUIDE VERSION 1.0 2018

3 4

FUNCTION

CONFIGURATION

The Q-Heat Distributor plays the following role in the XRGI® system:

■Separation of the engine circuit (primary) from the heating

network

■Protection of the primary circuit

■Control of the engine temperature

■Control of the system temperature

■Management of the storage load

■Management of the energy ﬂows

The Q-Heat Distributor separates the engine circuit (Power Unit

cooling water circuit) from the heating system by means of a plate

heat exchanger. In this way, the expansion vessel protects the engine

circuit. The circulation pump for the engine circuit is mounted on the

left of the primary circuit of the Q-Heat Distributor. When the Q-Heat

Distributor is connected to power, the circulation pumps run for 5–10

seconds to check that they are working properly.

The pumps cannot be conﬁgured. They start together with the Power

Unit and stop approx. 10–20 minutes after the Power Unit has shut

down. Their power is controlled by the Q-Heat Distributor according

to demand. The storage charge group (on the right of the Q-Heat

Distributor) controls the engine temperature via the mixer and the

speed-controlled circulation pump. The system is designed to maximi-

se the storage charge temperatures (80–85 °C).

The Q-Heat Distributor does not need to be adjusted after assembly.

2.1.3 QHEAT DISTRIBUTOR

Legend:

1Expansion vessel

2RJ45 connector

3Flow and return connection to the Power Unit

4Flow and return connection to the storage tank/consumer network

5Mixer for engine temperature control

6Plate heat exchanger (not visible)

CONSTRUCTION

Fig. 2.16 - Q20

Fig. 2.17 - Q80

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